WO2010029323A1 - Shaped heterogeneous catalysts - Google Patents
Shaped heterogeneous catalysts Download PDFInfo
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- WO2010029323A1 WO2010029323A1 PCT/GB2009/051051 GB2009051051W WO2010029323A1 WO 2010029323 A1 WO2010029323 A1 WO 2010029323A1 GB 2009051051 W GB2009051051 W GB 2009051051W WO 2010029323 A1 WO2010029323 A1 WO 2010029323A1
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- WIPO (PCT)
- Prior art keywords
- catalyst unit
- unit according
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- 239000002638 heterogeneous catalyst Substances 0.000 title description 5
- 239000003054 catalyst Substances 0.000 claims abstract description 97
- 238000000629 steam reforming Methods 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 23
- 239000000203 mixture Substances 0.000 claims description 18
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 230000003197 catalytic effect Effects 0.000 claims description 14
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 11
- 150000002736 metal compounds Chemical class 0.000 claims description 10
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 8
- 150000002739 metals Chemical class 0.000 claims description 8
- 239000000376 reactant Substances 0.000 claims description 8
- 229910052742 iron Inorganic materials 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 239000012254 powdered material Substances 0.000 claims description 7
- 238000002407 reforming Methods 0.000 claims description 7
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 6
- 230000015572 biosynthetic process Effects 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 238000003786 synthesis reaction Methods 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 230000000694 effects Effects 0.000 claims description 5
- 229930195733 hydrocarbon Natural products 0.000 claims description 5
- 150000002430 hydrocarbons Chemical class 0.000 claims description 5
- 230000003647 oxidation Effects 0.000 claims description 5
- 238000007254 oxidation reaction Methods 0.000 claims description 5
- 229910052763 palladium Inorganic materials 0.000 claims description 5
- 229910052697 platinum Inorganic materials 0.000 claims description 5
- 229910052707 ruthenium Inorganic materials 0.000 claims description 5
- 239000004215 Carbon black (E152) Substances 0.000 claims description 4
- GQPLMRYTRLFLPF-UHFFFAOYSA-N Nitrous Oxide Chemical compound [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 4
- 229910021529 ammonia Inorganic materials 0.000 claims description 4
- 229910052791 calcium Inorganic materials 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- 229910052749 magnesium Inorganic materials 0.000 claims description 4
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 claims description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 229910052787 antimony Inorganic materials 0.000 claims description 3
- 238000002453 autothermal reforming Methods 0.000 claims description 3
- NKCVNYJQLIWBHK-UHFFFAOYSA-N carbonodiperoxoic acid Chemical compound OOC(=O)OO NKCVNYJQLIWBHK-UHFFFAOYSA-N 0.000 claims description 3
- 238000006555 catalytic reaction Methods 0.000 claims description 3
- 238000001193 catalytic steam reforming Methods 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 238000000151 deposition Methods 0.000 claims description 3
- 229910052737 gold Inorganic materials 0.000 claims description 3
- 238000005470 impregnation Methods 0.000 claims description 3
- 229910052741 iridium Inorganic materials 0.000 claims description 3
- 229910052745 lead Inorganic materials 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 229910044991 metal oxide Inorganic materials 0.000 claims description 3
- 150000004706 metal oxides Chemical class 0.000 claims description 3
- 229910052750 molybdenum Inorganic materials 0.000 claims description 3
- 229910052758 niobium Inorganic materials 0.000 claims description 3
- 229910052700 potassium Inorganic materials 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 229910052702 rhenium Inorganic materials 0.000 claims description 3
- 229910052703 rhodium Inorganic materials 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 229910052708 sodium Inorganic materials 0.000 claims description 3
- 229910052718 tin Inorganic materials 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 229910052720 vanadium Inorganic materials 0.000 claims description 3
- 229910052727 yttrium Inorganic materials 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- 229910052785 arsenic Inorganic materials 0.000 claims description 2
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 claims description 2
- 238000000354 decomposition reaction Methods 0.000 claims description 2
- 230000008021 deposition Effects 0.000 claims description 2
- 239000012530 fluid Substances 0.000 claims description 2
- 229910001385 heavy metal Inorganic materials 0.000 claims description 2
- 238000005984 hydrogenation reaction Methods 0.000 claims description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 claims description 2
- 229910052753 mercury Inorganic materials 0.000 claims description 2
- 229910000000 metal hydroxide Inorganic materials 0.000 claims description 2
- 150000004692 metal hydroxides Chemical class 0.000 claims description 2
- 239000001272 nitrous oxide Substances 0.000 claims description 2
- 238000011084 recovery Methods 0.000 claims 1
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 7
- KDLHZDBZIXYQEI-UHFFFAOYSA-N palladium Substances [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 5
- 239000008188 pellet Substances 0.000 description 5
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Substances [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 5
- 239000007789 gas Substances 0.000 description 4
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 4
- KBJMLQFLOWQJNF-UHFFFAOYSA-N nickel(ii) nitrate Chemical compound [Ni+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O KBJMLQFLOWQJNF-UHFFFAOYSA-N 0.000 description 4
- 239000010949 copper Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000010970 precious metal Substances 0.000 description 3
- 229910052723 transition metal Inorganic materials 0.000 description 3
- 150000003624 transition metals Chemical class 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 2
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- 239000011575 calcium Substances 0.000 description 2
- 229910017052 cobalt Inorganic materials 0.000 description 2
- 239000010941 cobalt Substances 0.000 description 2
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- SXRIPRHXGZHSNU-UHFFFAOYSA-N iridium rhodium Chemical compound [Rh].[Ir] SXRIPRHXGZHSNU-UHFFFAOYSA-N 0.000 description 2
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 235000019359 magnesium stearate Nutrition 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 229910000480 nickel oxide Inorganic materials 0.000 description 2
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 1
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000011066 ex-situ storage Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 239000012255 powdered metal Substances 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000010944 silver (metal) Substances 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000003019 stabilising effect Effects 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
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- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
- C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
- C01B2203/0233—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being a steam reforming step
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
- C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
- C01B2203/0244—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being an autothermal reforming step, e.g. secondary reforming processes
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/025—Processes for making hydrogen or synthesis gas containing a partial oxidation step
- C01B2203/0261—Processes for making hydrogen or synthesis gas containing a partial oxidation step containing a catalytic partial oxidation step [CPO]
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0283—Processes for making hydrogen or synthesis gas containing a CO-shift step, i.e. a water gas shift step
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/10—Catalysts for performing the hydrogen forming reactions
- C01B2203/1005—Arrangement or shape of catalyst
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
- C01B2203/1205—Composition of the feed
- C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
- C01B2203/1235—Hydrocarbons
- C01B2203/1241—Natural gas or methane
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
- C01B2203/1205—Composition of the feed
- C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
- C01B2203/1235—Hydrocarbons
- C01B2203/1247—Higher hydrocarbons
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Definitions
- This invention relates to shaped heterogeneous catalysts.
- Heterogeneous catalysts are typically provided as particulate beds through which a liquid and/or gaseous reactant mixture is passed, often at elevated temperature and pressure. Therefore heterogeneous catalytic materials are often provided in shaped form to provide a balance of catalytic activity and throughput. In general smaller catalyst particles have a higher surface area and therefore activity, but provide lower throughput because the pressure drop through the catalyst bed is higher. To counter this, various catalyst designs have been used, which may have one or more through holes in an attempt to increase the geometric surface area and minimise pressure drop.
- WO 2004/014549 discloses shaped heterogeneous catalysts for gaseous reactions, comprising a cylindrical unit having a diameter to height ratio in the range between about 0.5:1 to 1 :1 and having a plurality of shaped holes of non-circular cross-section therethrough. Some embodiments additionally have V-shaped flutes running along the external length of the cylinder.
- both flutes and holes may increase the theoretical geometric surface area
- the effective geometric surface area when the units are placed in a packed bed for use can be significantly reduced by the packing of the catalyst.
- the flow of reactants through the holes can be much less than predicted due misalignment of the end faces of the cylindrical catalyst units either with other end faces or the cylindrical surface.
- the invention provides a catalyst unit in the form of a cylinder having a length C and diameter D, which has one or more holes extending therethrough, wherein said cylinder has domed ends of lengths A and B, such that (A+B+C)/D is in the range 0.50 to 2.00, and (A+B)/C is in the range 0.40 to 5.00.
- the invention further provides a method of making a catalyst unit comprising the steps of (i) feeding a powdered material, optionally with a pelleting aid, into a pelleting die, (ii) compressing the powder to form a shaped unit and then (iii) optionally heating the shaped unit to form the catalyst unit, said die being shaped such that the catalyst unit is in the form of a cylinder having a length C and diameter D, which has one or more holes extending therethrough, and the cylinder has domed ends of lengths A and B, such that (A+B+C)/D is in the range 0.50 to 2.00, and (A+B)/C is in the range 0.40 to 5.00.
- the invention further provides a catalytic process using the catalyst unit by contacting a reactant mixture, preferably a gaseous reactant mixture, with the catalyst unit under conditions to effect the catalysed reaction.
- catalyst units of the present invention that have these proportions, where the domed ends are relatively increased in size, provide a greater effective geometric surface area than prior art catalysts.
- the pressure drop performance of highly domed pellets when compared to pellets of equivalent diameter and length, which are only slightly or not domed is significantly better.
- This increase in performance is attributed to the extent of the dome on the pellet, which will cause the flowing medium to display less turbulent behaviour and reduce the overall energy losses experienced in the bed, therewith reducing the overall pressure drop.
- the domed surfaces will encourage radial mixing of the flow in the tube to compensate for the loss in turbulent mixing with respect to the overall radial heat transfer performance of the bed.
- the aspect ratio of the catalyst unit which may be defined as overall length divided by the diameter, i.e. (A+B+C)/D is in the range 0.5 to 2.0.
- (A+B+C)/D is in the range 0.75 to 1.50 as this reduces the tendency of the units to stack while at the same time providing a reduced tendency to break.
- One or both ends of the cylinder preferably both ends are domed.
- the domed ends have lengths A and B, which may be the same or different.
- the dome ratio to the cylindrical part of the catalyst unit i.e. (A+B)/C) is in the range 0.40 to 5.00, so as to provide a relatively highly domed structure. Below about 0.40 the effect of the dome is insufficient, whereas greater than about 5.0 the dome becomes difficult to fabricate.
- (A+B)/C is in the range 0.40 to 3.00, more preferably 0.50 to 2.50.
- the domed ends may form a segment of a circle or ellipse in cross-section, and desirably have a radius R > D/2.
- C is preferably in the range 1 to 25mm and D is preferably in the range 4 to 40 mm.
- the catalyst unit has one or more holes extending axially therethrough.
- the unit has between 1 and 12 holes extending therethrough, more preferably 3-10 holes, particularly 3-6 holes. Whereas larger units with 7 and 10 holes are known, these can, if the holes are sized to improve the geometric surface area, reduce the strength of the catalyst. Furthermore, the effectiveness and accessibility of catalyst units having 1 or 2 holes is potentially lower and so 3 to 6 holes are preferred.
- the holes should desirably be equally spaced and symmetrically positioned about the cross section of the cylinder so as to maximise the resulting strength of the catalyst. Thus 1 hole may be centrally positioned, 3 holes may be in a triangular pattern, 4 holes may be in a square pattern, 5 holes in a square pattern with a central hole, 6 holes may be in a hexagon pattern, and so on.
- the holes may be circular in cross-section or have one or more of the variety of cross-sections disclosed in the aforesaid WO 2004/014549. In a preferred embodiment, all the holes are circular in cross-section as this maximises the strength of the resulting catalyst unit.
- the holes may be the same size or different sizes.
- hole or holes have a circular cross-section and independently have a diameter d' in the range of 0.05D to 0.5D, more preferably 0.15D to 0.3D.
- the catalyst unit desirably has one or more flutes or channels running along its length.
- the flutes may be curved or straight or a combination thereof.
- Preferably the flutes are straight and run axially along the exterior of the catalyst unit as this simplifies fabrication.
- the shape of the flutes may be semicircular, elliptical, U-shaped, V-shaped, fl-shaped or a variant of these.
- the catalyst unit may have between 2 and 12 or more flutes, which desirably are symmetrically positioned , i.e. equally spaced around the circumference of the catalyst unit.
- the number of flutes equals the number of holes. In this arrangement, where, there is more than one hole, they should be positioned in the lobes created between the flutes or channels.
- the flutes are semi-circular or elliptical they may independently have a diameter d", width or depth in the range of 0.05D to 0.5D, preferably 0.15D to 0.333D.
- flutes and holes can provide optimised geometric surface area, voidage and strength.
- One preferred embodiment is a 4-hole, 4-fluted unit with circular holes and semicircular or elliptical flutes.
- one or both domed ends may be positioned to provide a lip on one or both ends of the cylinder portion of the shaped unit.
- the width, w', of the lip is desirably in the range 0.2 to 2 mm.
- the catalyst units may be fabricated from a powdered composition containing one or more catalytically active metals thereby generating the catalyst directly or may fabricated from one or more powdered catalyst support materials and the resulting unit then treated e.g. by impregnation or deposition with one or more metal compounds to form the catalyst.
- the catalyst unit may be fabricated using a powdered metal, metal oxide, metal hydroxide, metal carbonate, metal hydroxycarbonate or mixture thereof.
- Powdered compositions containing catalytically active metals may be prepared by mixing the respective metal oxides, carbonates, hydroxides or hydroxy-carbonates, or may be formed by known precipitation techniques, whereby a mixture of soluble salts is precipitated, e.g. using an alkaline precipitating agent, dried and optionally calcined and/or reduced & passivated.
- Preferred catalyst support materials are selected from powdered alumina, titania, zirconia, metal-aluminate, or a mixture thereof, which may contain one or more stabilising compounds such as Lanthana, silica and potassium oxide.
- Catalyst units fabricated with these may be termed shaped catalyst support units, and the final catalyst will therefore further comprise one or more metal compounds that have been impregnated into and/or deposited on said shaped catalyst support unit.
- the catalyst units preferably comprise one or more metals selected from Na, K, Mg, Ca, Ba, Al, Si, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Sn, Sb, La, Hf, W, Re, Ir, Pt, Au, Pb, or Ce.
- the catalyst units may be fabricated using any of the known catalyst formulations using established methods.
- the catalyst unit comprises one or more transition metals such as nickel, cobalt, iron or copper, and/or one or more precious metals such as platinum, palladium, rhodium iridium or ruthenium that are present in the form of the metal, an oxide, hydroxide, carbonate or hydroxycarbonate.
- transition metals such as nickel, cobalt, iron or copper
- precious metals such as platinum, palladium, rhodium iridium or ruthenium that are present in the form of the metal, an oxide, hydroxide, carbonate or hydroxycarbonate.
- the catalyst unit comprises one or more transition metals, such as nickel, copper, cobalt or iron and/or precious metals such as platinum, palladium, rhodium iridium or ruthenium, that have been impregnated into or deposited on a refractory catalyst support material such as an alumina-, calcium aluminate-, magnesium aluminate- or zirconia- based shaped catalyst support unit.
- transition metals such as nickel, copper, cobalt or iron and/or precious metals such as platinum, palladium, rhodium iridium or ruthenium, that have been impregnated into or deposited on a refractory catalyst support material such as an alumina-, calcium aluminate-, magnesium aluminate- or zirconia- based shaped catalyst support unit.
- the transition metal and precious metal content in such catalysts may be up to 85% by weight, but is preferably in the range 1-60% by weight. Pelleting is the preferred fabrication method for the present invention.
- the method for fabricating the catalyst unit may therefore comprise the steps of (i) feeding a powdered material, optionally with a pelleting aid or lubricant such as graphite or magnesium stearate, into a pelleting die, (ii) compressing the powder to form a shaped unit and then (iii) optionally heating the shaped unit to form the catalyst unit.
- the heating step which may include calcination, may be performed to increase the strength of the catalyst unit.
- the powdered material may comprise one or more catalytically active metals in a reduced and/or oxidised form, or may be a catalyst support material, in which case the final catalyst may be prepared by a separate step of impregnating a metal compound into and/or depositing a metal compound onto the shaped catalyst support unit.
- Known techniques may be applied in order to do this.
- a solution of nickel nitrate may be impregnated into the shaped catalyst support unit, dried, and calcined to cause the nickel nitrate to decompose thereby forming a nickel oxide-containing catalyst.
- the powdered material may be a precipitated composition comprising one or more catalytic metals that has been dried and optionally calcined and/or reduced & passivated.
- the catalyst units containing the catalytic metal compounds may be subjected to various treatments such as reduction with a hydrogen- and/or carbon monoxide-containing gas stream or sulphidation, e.g. with hydrogen sulphide, to render them active in use.
- the post treatment may be carried out ex-situ or in-situ, i.e. before or after installation in the reactor where it is to be used.
- the catalyst unit prepared according to the present invention may be applied to any heterogeneous catalytic process, but is preferably applied to fixed bed processes, more preferably fixed bed processes using gaseous reactants.
- the catalytic process therefore comprises contacting a reactant mixture, preferably a gaseous reactant mixture, with the catalyst under conditions to effect the catalysed reaction.
- the catalytic process may be selected from hydroprocessing including hydrodesulphurisation, hydrogenation, steam reforming including pre-reforming, catalytic steam reforming, autothermal reforming and secondary reforming and reforming processes used for the direct reduction of iron, catalytic partial oxidation, water-gas shift including isothermal-shift, sour shift, low-temperature shift, intermediate temperature shift, medium temperature shift and high temperature shift reactions, methanation, hydrocarbon synthesis by the Fischer-Tropsch reaction, methanol synthesis, ammonia synthesis, ammonia oxidation and nitrous oxide decomposition reactions.
- the catalyst units may also be used to recover heavy metals such as mercury and arsenic from contaminated gaseous or liquid fluid streams.
- a preferred use of the present invention is in the catalytic steam reforming of hydrocarbons wherein a hydrocarbon such as natural gas or naphtha is mixed with steam and passed at elevated temperature and pressure through a bed of catalyst units, typically comprising Ni or another group VIII metal on a refractory support, disposed in a plurality of externally-heated catalyst tubes.
- a hydrocarbon such as natural gas or naphtha
- Another preferred use is in autothermal reforming and secondary reforming, wherein a hydrocarbon-containing gas mixture is subjected to partial oxidation with oxygen or air and the resulting heated partially oxidised gas mixture passed through a fixed bed of steam reforming catalyst, again typically comprising Ni or another group VIII metal on a refractory support.
- Figure 1 is a side view depiction of a catalyst unit according to the present invention
- Figure 2 is an end view showing the top of the catalyst unit of Figure 1.
- Figures 1 and 2 together depict a catalyst unit 10 in the form of a cylinder 12 having a length C and diameter D, which has four symmetrically positioned holes 14 of circular cross-section extending therethrough. The centres of the four holes form an approximate square pattern. The diameter (d') of each of the four holes is about 0.18D.
- the cylinder 12 has domed ends 16, 18 of lengths A and B that form segments in cross-section. A and B are the same. (A+B+C)/D is about 1.10. (A+B)/C is about 0.75.
- the catalyst unit has four straight flutes 20 running along its length and equally-spaced around the circumference of the unit. The flutes are equidistant neighbouring holes, i.e. the centres of adjacent holes and the flute make a symmetrical triangle. The flutes are all semicircular and have a diameter (d") about 0.25D.
- the unit is provided with a lip 22 where the domed ends 16, 18 join the cylindrical portion 12.
- Examples 1a, 1 b and 1c relate to 4-holed 4-fluted highly domed cylindrical pellets similar to that depicted in Figures 1 and 2 but having elliptical flutes.
- Comparative shape X is similar to Examples 1a-d but with a doming ratio [(A+B)/C] of 0.13.
- a spray-dried alpha-alumina catalyst support material in powdered form was mixed with 0.0- 2.0% magnesium stearate and formed into shaped units as depicted in Figures 1 and 2 using a hydraulic press under normal operating conditions.
- the shaped unit was then heat-treated to 1100-1600 0 C to produce the required porosity and strength.
- the heat-treated shaped unit was then impregnated with an aqueous solution of nickel (II) nitrate and dried at 11O 0 C. The impregnation was repeated.
- the impregnated support was finally heated to 55O 0 C to convert residual nitrate to oxide.
- the final catalyst unit had a nickel oxide content in the range 5-20% by weight.
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Abstract
Description
Claims
Priority Applications (12)
Application Number | Priority Date | Filing Date | Title |
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RU2011114153/04A RU2488443C2 (en) | 2008-09-12 | 2009-08-24 | Moulded heterogeneous catalysts |
EP09785516.7A EP2323762B1 (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
DK09785516.7T DK2323762T3 (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
BRPI0918782A BRPI0918782A2 (en) | 2008-09-12 | 2009-08-24 | shaped heterogeneous catalysts |
CA2735972A CA2735972A1 (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
NZ591447A NZ591447A (en) | 2008-09-12 | 2009-08-24 | Cylindrical catalyst unit having circular holes extending therethrough |
CN200980135459XA CN102149465B (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
US13/063,613 US8557728B2 (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
AU2009290700A AU2009290700B2 (en) | 2008-09-12 | 2009-08-24 | Shaped heterogeneous catalysts |
JP2011526560A JP5575772B2 (en) | 2008-09-12 | 2009-08-24 | Molded heterogeneous catalyst |
EG2011030380A EG27134A (en) | 2008-09-12 | 2011-03-09 | Shaped heterogeneous catalysts |
ZA2011/01860A ZA201101860B (en) | 2008-09-12 | 2011-03-10 | Shaped heterogeneous catalysts |
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GBGB0816703.3A GB0816703D0 (en) | 2008-09-12 | 2008-09-12 | Shaped heterogeneous catalysts |
GB0816703.3 | 2008-09-12 |
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US (1) | US8557728B2 (en) |
EP (1) | EP2323762B1 (en) |
JP (1) | JP5575772B2 (en) |
KR (1) | KR101595598B1 (en) |
CN (1) | CN102149465B (en) |
AU (1) | AU2009290700B2 (en) |
BR (1) | BRPI0918782A2 (en) |
CA (1) | CA2735972A1 (en) |
DK (1) | DK2323762T3 (en) |
EG (1) | EG27134A (en) |
GB (1) | GB0816703D0 (en) |
NZ (1) | NZ591447A (en) |
PL (1) | PL2323762T3 (en) |
RU (1) | RU2488443C2 (en) |
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Also Published As
Publication number | Publication date |
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US20110201494A1 (en) | 2011-08-18 |
EP2323762B1 (en) | 2016-07-27 |
CA2735972A1 (en) | 2010-03-18 |
DK2323762T3 (en) | 2016-11-28 |
CN102149465B (en) | 2013-12-18 |
KR20110055727A (en) | 2011-05-25 |
ZA201101860B (en) | 2011-11-30 |
RU2011114153A (en) | 2012-10-20 |
KR101595598B1 (en) | 2016-02-18 |
CN102149465A (en) | 2011-08-10 |
EG27134A (en) | 2015-07-30 |
RU2488443C2 (en) | 2013-07-27 |
PL2323762T3 (en) | 2017-09-29 |
AU2009290700B2 (en) | 2014-03-13 |
AU2009290700A1 (en) | 2010-03-18 |
JP5575772B2 (en) | 2014-08-20 |
GB0816703D0 (en) | 2008-10-22 |
US8557728B2 (en) | 2013-10-15 |
JP2012501843A (en) | 2012-01-26 |
EP2323762A1 (en) | 2011-05-25 |
NZ591447A (en) | 2012-11-30 |
BRPI0918782A2 (en) | 2015-12-01 |
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